Introduction

A hydropower station in Assam required the replacement of its outdated and malfunctioning of control system for trash rack cleaning system. The existing system had become unreliable due to sensor damage and control failures, leading to operational inefficiencies and maintenance challenges.

Roadblock

The previous system was damaged, particularly the level sensor, resulting in:

• Inaccurate level detection
• Frequent manual cleaning
• Increased downtime and maintenance
• Plant personnel were dissatisfied due to repeated failures and lack of reliable automation.

They wanted to replace existing system and require reliable solution for monitoring and hydrostatic level transmitters to measure upstream and downstream level and control output to operate trash rack cleaning machine and provide end-to-end support including supply, installation supervision, and commissioning.

Solution

• We Supplied a new differential level control system along with a hydrostatic level transmitter tailored to site conditions.
• Supervised installation and commissioning to ensure seamless integration with existing infrastructure.
• Conducted on-site testing and calibration to validate system performance.

Result

• The new system was successfully commissioned and is now fully operational.
• Accurate level monitoring and automated trash rack cleaning have been restored.
• Plant personnel reported high satisfaction with the performance and reliability of the new control system.
• The upgrade has led to reduced manual effort, lower maintenance, and improved operational efficiency.

To learn more about our hydrostatic level transmitters, download our catalog here.